Tile replacement solar mounting system
A solar panel mounting system for use on flat and “S” tile roof structures includes a support arm coupled to a threaded post. A base flashing and corresponding attachment bracket are configured to couple with the post. A tile replacement flashing is installed over the base flashing and includes a conical protrusion with associated aperture. The aperture is configured to receive the post.
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This application claims the benefit of U.S. Provisional Patent Application No. 62/385,779, filed on Sep. 9, 2016, the content of which is incorporated by this reference.
BACKGROUNDSolar energy panels are becoming increasingly popular. However, current solar panel mounting solutions are overly complicated, not reliable, and otherwise inadequate. For example, current solar panel mounting solutions involve complicated systems for coupling a mounting system to a tile roof.
In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure.
The base flashing 150 can include through-holes 154 for allowing fasteners to traverse the base flashing 150 and to be fastened to the installation surface. Also, the through-holes 154 can be sized to allow the base flashing a degree of movement about a fastener until the fastener is tightly secured to the installation surface 152.
The base flashing 150 can include a ridge feature 156 that extends across the base flashing 150. The ridge feature 156 can be used to inhibit water from flowing into the region of the base flashing 150 containing the through-holes 154. For example, when an installation surface is sloped, the base flashing 150 can be positioned with the ridge feature 156 up-slope from the through-holes 154. In this configuration, water flowing down-slope on the installation surface is inhibited by the ridge feature 156 and prevented from reaching the through-holes 154. In some cases, the surfaces of the ridge feature 156 are configured at angles that allow the base flashing 150 to stack on a like base flashing 150. Also, in some cases, the ridge feature 156 has a geometry that prevents water from pooling along its surface. For example,
The tile replacement solar panel frame mounting system 100 can also include an attachment bracket that supports the post 130.
The attachment bracket 160 also includes a post slot 169 in the raised center section 162. The post slot 169 can be configured to accept a coupling feature of a post, e.g. a T-bolt, cam fastener, etc. (explained in greater detail below). The post slot 169 can have an extended length (i.e. along the x-axis) to allow the post to be coupled in a variety of positions within the post slot 169. Also, the multiple attachment slots 168 allow the attachment bracket 160 to be fastened in a variety of positions relative to a roof joist, stud, etc. Additionally, the raised center section 162 can be truncated to occupy only a portion of the length (i.e. along the x-axis) of the attachment bracket 160—leaving a gap 163 or a flat center portion (not shown). The gap 163 or flat center portion defined by the truncated raised center section 162 can accommodate the attachment bracket 160 being partially positioned under an adjacent tile.
The multiple attachment slots 168 can also extend along a width (i.e. the y-axis) of the flat sections 164, 166 to allow the attachment bracket 160 to be adjusted up and down on an installation surface. The attachment slots 168 can be sized to allow the attachment bracket 160 a degree of movement about one or more fasteners until the fastener(s) is tightly secured to the installation surface 152. Furthermore, the extended post slot 169 and the multiple attachment slots 168 allow the attachment bracket to be fastened to a roof joist, etc., in a variety of positions while the post 130 remains in the same position relative to the installation surface and tiles. Moreover, the adjustability provided by the extended post slot 169, the multiple attachment slots 168, the extended width of the attachment slots 168, and the truncated raised center section 162 provide synergistic adjustment effects in both the x-axis and y-axis directions. The extended post slot 169 may provide additional x-axis flexibility to position the post 130 after the attachment bracket 160 has already been secured to installation surface 152. In some cases, the attachment bracket 160 can be formed of a single piece of sheet metal. Also, the attachment bracket 160 can be formed without having any orthogonal features, thereby allowing multiple attachment brackets to be stackable with one another.
The conical protrusion 144 can be configured with an angle of protrusion from the plane of the tile replacement flashing 140 that is selected for one or more design objective. For example, the conical protrusion 144 can be non-orthogonal to the plane of the tile replacement flashing 140. In these cases, the conical protrusion 144 is configured with angle of protrusion from the plane of the tile replacement flashing 140 that accounts for an angle of a roof such that the post is perpendicular to the installation surface 152 when installed within the tile replacement solar panel frame mounting system 100. The tile replacement flashing 140 can also include a chamfer 148 on a corner of the top surface to facilitate easier manufacturing of the tile replacement flashing 140. In the embodiment shown, the chamfer 148 reduces the drawing required of the metal on the corner of the tile replacement flashing 140 where it interlocks with adjacent roof tile and forms down to meet the roof tile below.
Some embodiments of the present invention involve a tile replacement flashing with upward and/or downward protruding stiffening ribs formed into its planar surface.
Additionally, the post 130 can have a length to accommodate roofing tiles having a wide range of thicknesses and types (e.g. flat roofing tiles, S-type roofing tiles, ridge-type roofing tiles, Spanish-type roofing tiles, etc.). In some embodiments, post 130 may have all or a portion 139 of its body truncated to allow for a wrench to easily grip and rotate said post 130, as shown in
Also, the aperture 146 of the conical protrusion 144 of the tile replacement flashing 140 can be configured to allow the coupling mechanism 136 of the post 130 to be coupled with the attachment bracket 160 before or after the tile replacement flashing 140 is installed over the attachment bracket 160. This allows an installer to be able to install the tile replacement solar panel frame mounting system 100 without having to lift adjacent tiles when sliding in the tile replacement flashing 140.
In some cases, the attachment bracket 160 can be coupled with the post 130 and the tile replacement flashing 140 can be placed over the post 130 before fastening the attachment bracket 160 to the installation surface 152. The tile replacement flashing 140 can be removed to expose an area over the installation surface where the post can be located when the tile replacement flashing is finally installed. Next, the attachment bracket 160 can be adjusted (e.g. by selecting the appropriate attachment slots 168) to allow the post to be positioned within the appropriate area and to allow attachment slots 168 to align with a joist, stud, etc.
The various embodiments described above are provided by way of illustration only and should not be construed to limit the scope of the disclosure. Those skilled in the art will readily recognize various modifications and changes that may be made to the principles described herein without following the example embodiments and applications illustrated and described herein, and without departing from the spirit and scope of the disclosure.
Claims
1. A solar panel mounting assembly comprising:
- an attachment bracket having at least one flat section and a raised section, wherein the raised section includes a post slot;
- a post with a first internal threaded section on a first terminal end of the post and a second threaded section on a second terminal end of the post;
- a threaded T-bolt coupling mechanism, the threaded T-bolt cooperating with the first internal threaded section and configured to traverse the post slot of the attachment bracket and couple the post with the attachment bracket; and
- a tile replacement flashing having a top surface and at least one side surface defining a cavity opposite the top surface, wherein the top surface includes a conical protrusion extending away from the top surface, the conical protrusion including an aperture configured to allow the post and the threaded T-bolt to traverse therethrough.
2. The solar panel mounting assembly of claim 1, further comprising at least one attachment aperture along a length of the flat section of the attachment bracket, wherein the at least one attachment aperture comprises an extended aperture configured to receive a fastener.
3. The solar panel mounting assembly of claim 2, further comprising:
- a base flashing having a substantially flat surface, at least one through-hole, and a ridge feature, wherein the base flashing is configured to be installed on an installation surface such that the ridge feature is configured to protect the at least one through-hole from moisture flowing down an installation surface towards the at least one through-hole, and wherein the at least one through-hole is configured to align with the at least one attachment aperture when the attachment bracket is adjusted on the base flashing.
4. The solar panel mounting assembly of claim 3, wherein the ridge feature is configured in a chevron shape with a peak of the chevron shape being at a distance further away from the at least one through-hole than a distance away from an arm of the chevron shape.
5. The solar panel mounting assembly of claim 3, wherein the ridge feature is configured as a triangular ridge extending away from the substantially flat surface.
6. The solar panel mounting assembly of claim 1, wherein the post slot extends a length of the raised section of the attachment bracket.
7. The solar panel mounting assembly of claim 1, wherein the raised section of the attachment bracket is raised in only a portion of the length of the attachment bracket.
8. The solar panel mounting assembly of claim 1, wherein the post further includes an exterior non-threaded section between the first terminal end and the second terminal end.
9. The solar panel mounting assembly of claim 1, wherein the second threaded section on the second terminal end of the post is an internal threaded section.
10. The solar panel mounting assembly of claim 1, wherein the second threaded section on the second terminal end of the post is an external threaded section.
11. The solar panel mounting assembly of claim 1, wherein the tile replacement flashing includes at least one downward protruding face at a corner of the flashing formed without an aperture at the corner and stiffening ribs are formed into the top surface for rigidity.
12. The solar panel mounting assembly of claim 1, wherein a first dimension of the aperture is larger than a second dimension of the threaded T-bolt coupling mechanism and a cross-sectional dimension of the post such that the threaded T-bolt coupling mechanism and post freely fits through the aperture.
13. The solar panel mounting assembly of claim 1, further comprising a rubber boot configured to seal the aperture from moisture entering the aperture when the post is inserted therethrough.
14. The solar panel mounting assembly of claim 1, further comprising:
- a support arm assembly having an internal threading and an arm, the internal threading of the support arm cooperating with the second threaded section on the second terminal end of the post; and
- a mounting clamp assembly having a top clamp and a bottom clamp, wherein the top clamp is installed on the support arm assembly when a fastener is inserted through the top clamp, the bottom clamp, and tightened with a fastener nut.
15. The solar panel mounting assembly of claim 1, further comprising:
- an extender arm having an internal cavity for mating with the post, an extension section, and a vertically protruding threaded post.
16. The solar panel mounting assembly of claim 15, wherein the extension section is a sloping extension section that slopes down away from the first internal threaded section, and wherein the vertically protruding threaded post is configured with a height that brings vertically protruding threaded post to a top height of the first internal threaded section.
17. The solar panel mounting assembly of claim 1, wherein the conical protrusion prevents water from entering the aperture.
18. A solar panel mounting assembly comprising:
- an attachment bracket having at least one attachment aperture and a post slot along a length of the attachment bracket;
- a post with an internal threaded section on a terminal end of the post;
- a threaded T-bolt, the threaded T-bolt cooperating with the internal threaded section of the post and configured to traverse the post slot of the attachment bracket and couple the post with the attachment bracket; and
- a tile replacement flashing having a top surface and at least one side surface defining a cavity opposite the top surface, wherein the top surface includes a conical protrusion extending away from the top surface, the conical protrusion including an aperture configured to allow the post and the threaded T-bolt to traverse therethrough.
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Type: Grant
Filed: Sep 7, 2017
Date of Patent: Mar 24, 2020
Patent Publication Number: 20180076756
Assignee: PEGASUS SOLAR INC. (Richmond, CA)
Inventors: Erich Kai Stephan (Newport Beach, CA), Glenn Harris (Sausalito, CA)
Primary Examiner: Patrick J Maestri
Assistant Examiner: Joseph J. Sadlon
Application Number: 15/698,521
International Classification: H02S 20/25 (20140101); H02S 30/10 (20140101); F16B 5/02 (20060101); H02S 40/00 (20140101); H02S 20/23 (20140101); H02S 30/00 (20140101); F16B 21/02 (20060101);